Pattern shearing device for pile fabrics

ABSTRACT

A textile shear having a blade and an endless belt with an embossed surface for supporting a pile fabric adjacent the knife. The endless belt, mounted on supporting means pivotable about a vertical axis for ease in pattern changing, includes longitudinal ridges to prevent longitudinal sliding thereof along a driven supporting roller and a carved pattern portion more elastic than the portion thereof being driven.

United States Patent [191 Davidson [11] 3,818,554 June 25, 1974 1PATTERN SHEARING DEVICE FOR PILE FABRICS [75] Inventor: Ralph L.Davidson, Worcester,

Mass.

[73] Assignee: Curtis & Marble Machine Company, Worcester, Mass.

22 Filed: Jan. 31, 1972 21 Appl. No.: 222,075

[52] US. Cl 26/16, 198/124, 198/202 [51] Int. Cl D06C 23/02 [58] Fieldof Search 26/16, 70; 198/124, 125, 198/202 [56] References Cited UNITEDSTATES PATENTS 249,859 11/1881 Smith 26/16 288,109 11/1883 Pharr 198/124X 403,682 5/1889 Lowden 26/16 1,033,317 7/1912 Hartley 198/125 1,628,4365/1927 Segrin et al 198/202 1,708,763 4/1929 Huss et al. 26/16 1,737,08511/1929 Horstmann 26/16 2,470,575 5/1949 Norton 26/70 2,977,660 4/1961Gebert et a1 26/16 3,327,839 6/1967 Sigety et a1. 198/202 OTHERPUBLICATIONS Carpet and Rug Progress, by Reg. Burnett, Modern Textiles,November, 1970, pps. 39, 42.

Primary Examiner-Robert R. Mackey Attorney, Agent, or Firm-Norman S.Blodgett; Gerry A. Blodgett 57] ABSTRACT A textile shear having a bladeand an endless belt with an embossed surface for supporting a pilefabric adjacent the knife. The endless belt, mounted on supporting meanspivotable about a vertical axis for ease in pattern changing, includeslongitudinal ridges to prevent longitudinal sliding thereof along adriven supporting roller and a carved pattern portion more elastic thanthe portion thereof being driven.

3 Claims, 11 Drawing Figures SHEET 2 [IF 5 PAIENTtnaunzsmu PATENTEDJuuzsmm sum 3 u; s

1 PATTERN SHEARING DEVICE FOR PILE FABRICS BACKGROUND OF THE INVENTIONIn the manufacture of textiles and, particularly pile fabric, it iscommon practice to make the pile to a shorter length in some areas thanin others to provide a sculptured surface. This can be done when thepile is formed on a tufting machine, but in such a case, the pattern issubstantially built into the machine, so that it is difficult to obtainany variety in sculpturing by this method. Furthermore, such machinesare very expensive and difficult to maintain. It has been suggested inthe past that the tufted fabric be manufactured on the machine withtufts that are all of the same size and, then, in a secondary operation,to obtain the sculpturing by cutting. The project of accomplishing it inthis way is particularly desirable because of the fact that shearing isa necessary secondary operation in any case. This has been done byintroducing into the conventional shear an added configured roll overwhich the tufted fabric passes. The high spots in the roll press thetufts closer to the shear and the low spots allow it to pass by theshear at a greater distance. The difficulty experienced, however, hasbeen that, when such a configured roll was small in diameter, thecutting of the tufts took place adequately, but the pattern repeateditself every circumference of the roll and variety in pattern was notpossible. When attempts were made to make the roll larger in diameter(so that the circumference would be greater and the patternrepeatability less frequent), the shear was not able to cut the tuftadequately because the fabric was not passing around a sharp enoughradius in the vicinity of the shear. These and other difiicultiesexperienced with the prior art devices have been obviated in a novelmanner by the present invention.

It is, therefore, an outstanding object of the invention to provide atextile shear for producing a sculptured pile fabric having substantialvariety in pattern.

Another object of this invention is the provision of a textile shear foruse with pile fabric in which the distance within which the patternrepeats. can be as long as desired.

A further object of the present invention is the provision of a shearfor use with pile fabric in which the fabric is held on a sharp radiusof curvature at the point of shearing and yet the pattern does notrepeat frequently.

It is another object of the instant invention to provide a shear forproducing a sculptured effect on pile fabric in which the pattern changetakes place at long distances along the length of the fabric and doesnot make use of a configured roll of large diameter.

A still further object of the invention is the provision of a shear foruse in sculpturing tufted fabric in which the pattern produced is easilychanged.

With these and other objects in view, as will be apparent to thoseskilled in the art, the invention resides in the combination of partsset forthin the specification and covered by the claims appended hereto.

SUMMARY OF THE INVENTION In general, the invention consists of a textileshear having a rotary knife mounted for rotation about a first axis anda bed knife located adjacent the path of the knife as it rotates. Aroller is mounted for rotation LII about an axis which is parallel toand spaced from the said first axis and an endless belt extends aroundthe roller and has an embossed surface directed toward the rotary knife.

More specifically, the roller is mounted for swinging action about oneend on occasion on an axis which is perpendicular to the said firstaxis.

The invention also consists of a method for patternshearing a tuftedfabric consisting of the steps of passing the tufted fabric undertension between a rotary knife and a roller having a radius of curvaturesubstantially less than that of the rotary knife; the fabric is drawnover the roller away from the rotary knife to subtend a substantialportion of the periphery of the roller and the fabric is interposedbetween the roller and an embossed element.

The invention also includes a belt for the patternshearing of tuftedfabric having an endless driven portion of substantial width formed ofrelatively inelastic material and a carved portion fastened to onesurface of the driven portion and formed of a relatively elasticmaterial.

The invention also includes a method of forming a carved belt comprisingthe steps of providing an endless portion of substantial width formed ofa relatively inelastic material and providing a layer of easily carvedmaterial for attachment to one surface of the said portion. A pattern isthen applied to the surface of the layer, parts of the layer are removedin accordance with the pattern to form recesses exposing the saidsurface of theelement, and pouring an elastic plastic into the recessesfor attachment to the surface of the element exposed by the surfaces.The remainder of the said layer is then removed.

BRIEF DESCRIPTION OF THE DRAWINGS The character of the invention,however, may be best understood by reference to one of its structuralforms, as illustrated by the accompanying drawings, in which:

FIG. 1 is a perspective view of a textile shear incorporating theprinciple of the present invention,

FIG. 2 is a vertical sectional view of the invention taken on the lineII-II of FIG. 1,

FIG. 3 is a vertical sectional view of a portion of the textile shear,

FIG. 3A is a perspective view of a portion of the shear,

FIG. 4 is a view of a portion of the shear taken on the line IV-IV ofFIG. 3,

FIG. 5 is a perspective view of a portion of the shear,

FIG. 6 is a sectional view of the shear taken on the line VlVl of FIG.5, and

FIGS. 7 through IOiIIustrate various steps of forming the belt, which ispart of the shear.

DESCRIPTION OF THE PREFERRED EMBODIMENT Referring first to FIG. 1,wherein are best shown the general features of the invention, thetextile shear, indicated generally by the reference numeral 10, is shownin use with a metal detector apparatus 1 l, a front frame 12, a frontshear section 13, a guiding system 14, a guider sensor and positioner15, all leading, finally, to the textile shear 10, which is the subjectof the present invention. Both the shear 10 and the front shear section13 are provided with vacuum lint operators 16 and 17, respectively.

Referring to FIG. 2, it can be seen that the guiding system 14 isprovided with a roll 30 over which the fabric 18 passes, this roll beingprovided with a brake for providing a drag on the fabric as it passesthrough the various pieces of equipment. The shear is provided near itsoutput with a drive roll 19 which pulls the fabric through the mainoperating parts of the shear 10. An idler roll 20 is resiliently mountedbetween the operative area of the shear and the drive roll 19. The shear10 is provided with a rotary knife 21, a bed knife 22, and a roller 23,as well as a belt 24 passing around the roller 23 and hanging down intothe body of the housing of the shear.

In FIG. 3 it can be seen that the rotary knife 21 is provided withhelical blades 25 and is mounted for rotation about a horizontal axis. Abed knife 22 is mounted adjacent the rotary knife 21 with its operatingedge lying almost exactly under the horizontal axis about which thatknife rotates. The roller 23 is mounted abouta horizontal axis which isparallel to and spaced from the axis of the rotary knife 21 and theendless belt 24 passes over the roller 23 in the same direction that thefabric 18 passes. The fabric 18 is shown as in the form of tufted fabrichaving tufts 26 which are directed toward the blades 25 of .the knife21, the undersurface of the fabric engaging the belt 24 which isprovided with upwardly extending bosses 27. For the purposes of thisapplication, the expression bosses is used to indicate raised portionsof the belt, but may have any desired pattern or configuration. Theunderside of the belt 24 is provided with a ridge 28 which engages asuitable V-shaped groove 29 formed at one end of the roll 23 to guidethe belt against movement longitudinally of the axis of the roll 23.

FIG. 4 shows the appearance of the belt 24 including the raised portionsor bosses 27. It also shows the location of the ridge 28 at one end ofthe belt as well as a similar ridge 31 at the other end of the belt. Thebelt consists of a driven portion 32 of substantial width formed of arelatively inelastic material and a carved portion consisting of thebosses 27 fastened to the upper surface of the driven portion and formedof a relatively elastic material which, in the preferred embodiment, ispolyurethane of 50 durometer. The basic belt or driven portion 32 is thefabric impregnated with rubber.

As is evident in FIGS. 5 and 6, the roller 23 is mounted for swingingaction about one end on occasion, the axis of swinging being vertical orat right angles to the horizontal plane in which the rotary shear 21 isrotated. The roller has a diameter which is substantially smaller thanthat of the blade 25 of the rotary knife 21 and is rotatably mounted ona beam 33 which swings about the same axis. The beam 33 at the other endis provided with a latching mechanism 34 to hold it in place duringnormal operation. The bottom of the beam 33 adjacent the latchingmechanism 34 slides along and is supported by a horizontal beam 35forming part of the framework of the housing of the machine.

Extending from the housing of the shear is an abutment 37 having avertical drive shaft 38 suitably mounted in bearings acting both as ahinge pivot and as a drive shaft. The top of the shaft 38 is providedwith a bevel gear 39 which engages a bevel gear 41 on the roller 23.Suitable guide shafts 42 extend parallel to the surface of the beam 33,so that the inner surface of the belt 24 has smooth, round surfaces topass around. The roller 23 and the drive roll 19 are driven by the samemotor 43 and a drive means 44 connects the motor to the roller 23 andthe drive roll 19 to cause the roller to have a peripheral speedsubstantially less than that of the drive roll, so that the drive rollcontrols the speed of the fabric 18.

The operation of the invention will now be readily understood in view ofthe above description, the apparatus provides a method forpattern-shearing of a tufted fabric consisting of the steps of passingthe pile fabric 18 under tension between the rotary knife 21 and theroller 23 having a radius of curvature substantially less than that ofthe rotary knife. The fabric 18 is drawn over the roller 23 as shown inFIG. 3 and directed away from the rotary knife 21 to subtend asubstantial portion of the periphery of the roller, the fabric 18passing between the roller 23 and its belt 24, on the one hand, and therotary knife 21, on the other hand. The roller 23 is driven at aperipheral speed which is substantially less than the linear speed ofthe fabric as it passes between the rotary knife and the roller. Thebosses 27 on the belt 24 cause similar portions of the fabric 18 to beraised higher than the portions which have no bosses, so that the rotaryknife 21 by means of its blade 25 operative with the bed knife 22 canshear the raised parts of the tufts 26 shorter than the others. Afterthe fabric passes the roller 23 and the belt 24, the fabric returns toits former condition, but the raised tufts are now shorter andconstitute cavities in the tufted fabric,

Referring now to FIGS. 7 through 10, it can be seen that a method isdescribed for forming the belt 24 for the pattern-shearing of tuftedfabric. The belt consists of an endless driven portion 32 of substantialwidth formed of a relatively inelastic material which, in the preferredembodiment, is a fabric which is rubberimpregnated. A suitable V-shapedridge 28 is provided for guiding the belt on the roll 23.

Referring to FIG. 10, a carved portion 27a remains after the operationis completed. In FIG. 7, a sheet 45 of relatively easily carvedmaterial, such as expanded polyethylene, is applied to the upper surfaceofthe driven portion 32. A pattern or design 46 is drawn on its surfaceand a cut is made down to the upper surface of the driven portion 32. Inthe preferred embodiment, a margin 47 is left.

In FIG. 8, the remainder part of the sheet 45 is drawn away leaving thebosses 46 and the raised margin 47. Then, as shown in FIG. 9, liquidpolyurethane is poured into the cavity and brought up to the same levelas the elements 46 and 47, thus forming the carved portion 27A. Finally,the rest of the expanded polyethylene elements 46 and 47 are removed, asshown in FIG. 10, pulled away and discarded, leaving the recesses whichlie between the bosses or carved portion 27A. The upper surface of thedriven portion 32 can be seen exposed in the recesses that are left.Normally, this operation would be done with a complete loop, but it ispossible to do so with the ends of the belt unattached, so that thedriven portion 32 is a flat plate. After the operation is completed, itis then necessary to fasten the ends together to form the belt 24.

It can be seen that the present invention provides a very desirable andflexible manner of providing a patterned cutting or shearing of thetufted fabric 18. When it is necessary to change the pattern, it is onlyessential to change the belt 24 by releasing the latching mechanism 34and swinging the roller 23 along with its beam 33 outwardly about thepivot shaft 38. The new belt is slid on and the beam 33 swung back intoits original position transversely of the shear and the latchingmechanism 34 re-fastened. The belt 24 can be made as long a loop as isdesirable to provide for infrequent change of pattern or lowrepeatability. The method of making the belt is inexpensive and allows agreat latitude in selection of pattern. Furthermore, the making of abelt can take place in the textile plant in which the shear is used sothat a changeover of pattern takes very little time.

It is obvious that minor changes may be made in the form andconstruction of the invention without departing from the material spiritthereof. It is not, however, desired to confine the invention to theexact form herein shown and described, but it is desired to include allsuch as properly come within the scope claimed.

The invention having been thus described, what is claimed as new anddesired to secure by Letters Patent is:

l. A textile shear comprising:

a. a rotary knife mounted for rotation about a first axis,

b. a bed knife located adjacent the path of the rotary knife as itrotates,

c. a roller mounted for rotation about an axis which is parallel to andspaced from the said first axis, the roller being also mounted forswinging action about one end on occasion about a second axes which isperpendicular to the said first axis the roller having a diametersubstantially smaller than the rotary knife and being rotatably mountedon a beam which swings about the second axis,

(1. a belt extending around the roller and having an embossed surfacedirected toward the rotary knife, the driven portion of the belt havinga plurality of longitudinal ridges that engage peripheral grooves formedon the roller to prevent the belt from sliding longitudinally of theroller, the belt consisting of a drive portion that lies against theroller and a carved portion that carries a tufted fabric and holds itagainst the rotary knife, the carved portion being substantially moreelastic than the driven portion,

the said swing axis.

1. A textile shear comprising: a. a rotary knife mounted for rotationabout a first axis, b. a bed knife located adjacent the path of therotary knife as it rotates, c. a roller mounted for rotation about anaxis which is parallel to and spaced from the said first axis, theroller being also mounted for swinging action about one end on occasionabout a second axes which is perpendicular to the said first axis theroller having a diameter substantially smaller than the rotary knife andbeing rotatably mounted on a beam which swings about the second axis, d.a belt extending around the roller and having an embossed surfacedirected toward the rotary knife, the driven portion of the belt havinga plurality of longitudinal ridges that engage peripheral grooves formedon the roller to prevent the belt from sliding longitudinally of theroller, the belt consisting of a drive portion that lies against theroller and a carved portion that carries a tufted fabric and holds itagainst the rotary knife, the carved portion being substantially moreelastic than the driven portion, e. a drive roll and a tension rollprovided to direct a tufted fabric through the space between the rotaryknife and the belt at a controlled tension.
 2. A textile shear asrecited in claim 1, wherein the other end of the roller and beam isprovided with a latching mechanism to hold it in place during normaloperation.
 3. A textile shear as recited in claim 1, wherein the rolleris driven for rotation by a shaft that is coaxial of the said swingaxis.